General Repair Instructions

General repair instructions, 02M, 5 and 6 Spd. M/T
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when performing vehicle repairs.

A number of generally valid instructions applicable for the various repair procedures are summarized here.

Transmission
- When installing ensure that the dowel sleeves between the engine and the transmission are correctly located.
- When assembling mounting brackets as well as other waxed components the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.
- When changing a transmission fill it with gear oil to the lower edge of the filler hole.
- Capacities and specifications.

Gaskets, sealing rings





- Before installing oil seal, fill space between sealing lips with grease G 052 128 A1 (arrows).
- After installing, check oil level.
- Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
- Apply sealant uniformly but not too thick.
- Replace O-rings.

Locking devices
- Replace circlips.
- Do not overstretch circlips.
- Circlips must locate properly in the groove.





- Replace spring pins. Installation position: slot longitudinal to line of force.

Bolts and nuts
- Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
- Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten nuts and bolts in stages in a diagonal sequence.
- Tightening torques as specified are for unoiled bolts and nuts.
- Replace self-locking bolts and nuts.
- Ensure that on bolted connections the areas around the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly, if necessary.

Bearings
- Install new tapered roller bearings as supplied and do not lubricate additionally.
- Install needle bearings with lettered side (thicker metal) towards fitting tool.
- Tapered roller bearings fitted to one shaft must be replaced as a set. Use the same make of bearings.
- Heat inner races to approximately 100°C before installing.
- Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.

Shims
- Measure shims at several points with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
- Check for burrs and damage.
- Only install perfect shims.

Synchronizer rings
- Do not interchange. When reusing always fit to the same gear.
- Check for wear and replace if necessary.
- Coat with gear oil before installing.

Selector gears
- Before installing clean and heat on a hot plate to approximately 100°C.
- Temperature can be checked with temperature tester V.A.G 1558.